EP3640012A1 - Method and system for reworking a composite laminate - Google Patents

Method and system for reworking a composite laminate Download PDF

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Publication number
EP3640012A1
EP3640012A1 EP18382747.6A EP18382747A EP3640012A1 EP 3640012 A1 EP3640012 A1 EP 3640012A1 EP 18382747 A EP18382747 A EP 18382747A EP 3640012 A1 EP3640012 A1 EP 3640012A1
Authority
EP
European Patent Office
Prior art keywords
tape
defective
reworking
catching
composite
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP18382747.6A
Other languages
German (de)
French (fr)
Other versions
EP3640012B1 (en
Inventor
José Manuel MENÉNDEZ MARTÍN
Raúl Alberto CABAÑAS CONTRERAS
Pedro CABRERA RODRÍGUEZ
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Airbus Operations SL
Original Assignee
Airbus Operations SL
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Airbus Operations SL filed Critical Airbus Operations SL
Priority to EP18382747.6A priority Critical patent/EP3640012B1/en
Priority to CA3056864A priority patent/CA3056864A1/en
Priority to KR1020190125755A priority patent/KR102502355B1/en
Priority to US16/655,414 priority patent/US11104084B2/en
Priority to CN201910994173.2A priority patent/CN111070731B/en
Publication of EP3640012A1 publication Critical patent/EP3640012A1/en
Application granted granted Critical
Publication of EP3640012B1 publication Critical patent/EP3640012B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
    • B29C70/386—Automated tape laying [ATL]
    • B29C70/388—Tape placement heads, e.g. component parts, details or accessories
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
    • B29C70/386—Automated tape laying [ATL]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/545—Perforating, cutting or machining during or after moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C73/00—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
    • B29C73/04—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements
    • B29C73/10—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements using patches sealing on the surface of the article
    • B29C73/12—Apparatus therefor, e.g. for applying
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B43/00—Operations specially adapted for layered products and not otherwise provided for, e.g. repairing; Apparatus therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/0081—Shaping techniques involving a cutting or machining operation before shaping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B41/00—Arrangements for controlling or monitoring lamination processes; Safety arrangements
    • B32B2041/04—Detecting wrong registration, misalignment, deviation, failure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/08—Reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/18—Aircraft

Definitions

  • the invention relates to the automated manufacturing of fibre reinforced composite laminates by using automated tape or tow placement machines.
  • the invention is applicable to all the parts of the structure of an aircraft or any composite part out of aerospace field.
  • Laminates comprising a plurality of plies of composite are known, these laminates are being laid up by an automated tape placement machine comprising a laying head which lays one tape or a plurality of tapes per trajectory of the laying head.
  • the plurality of tapes laid in a trajectory are usually named as course.
  • Figure 1 shows a schematic of a typical tape placement machine end effector with two laying heads.
  • the tape is clamped and cut using a blade or alternative system, for instance, in figure 2 the clamping is done using the adding rollers.
  • the rework has to be done manually by an operator using a blade knife or other instrument to remove the defective tape.
  • the replacement of the removed tapes can be then done manually or using again the automated placement machine.
  • the object of the invention is the improvement of the automated process of manufacturing composite laminates.
  • the advantages with respect to the prior art are the systematisation of the rework process, improving the quality of the laminate after the rework, the eventual lead time and labour savings and the enabling of full automation of the composite laying operations.
  • the detection of the defect is performed simultaneously to the laying up process of the tape.
  • the use of an online automated inspection system to detect the occurrence of a defect during the laying process is used, although the detection can have different levels of automation, from direct visual detection by an operator up to real time full automated defect detection/identification implying the coordination with a defect detection system.
  • the lay-up process of the defective tape is continued until the end of the course, specifically extending an additional length over the predetermined or design length of the tape.
  • the head of the machine could perform a movement to separate the laying head from the laminate, in one embodiment allowing the deployment of the rework system.
  • the next operation will be catching and removal of the defective tape or tapes by the catching system itself.
  • the rework system may retract to avoid interference with the laying heads and the replacement tapes will be laid by the machine as previously stated.
  • the catching step and the cutting step may be performed in any order as long as the defective tape is cut and catch by the catching system.
  • the reworking system object of the invention comprises the catching system comprising means configured for catching the defective tape when the occurrence of a defect on the tape or plurality of tapes is detected during the laying of the tape and comprising means for removing the caught defective tape from the laminate.
  • the automated tape placement machine object of the invention therefore comprises a reworking system according to the above and further comprises:
  • Figure 1 discloses a known automated taped placement machine manufacturing a laminate (1) over a mould (100) by laminating tapes (2) by means of two heads comprising at least a pressure roller (6), addition rollers (5) and cutters (50).
  • the tape (2) is clamped using the adding rollers (5) and cut using a blade or alternative system to end the laying.
  • Figure 3 shows the detection of a defect (3) on a tape (4) while the tape (4) is being laid up. Afterwards, the lay-up of the defective tape (4) is continued until a tape (4) length that surpasses the manufacturing length (L) of the tape (4) as represented in figure 4 . By rotation of the adding rollers (5) the defective tape (4) is placed between the pressure roller (6) and the laying surface to continue the lying operation.
  • the catching system is deployed after detecting the occurrence of a defect (3) and retracted after removal of the defective tape (4).
  • the lying head may be separated from the defective tape (4), more specifically, as shown in figure 5 , the pressure roller (6) is lifted from the laminate (1).
  • the catching system of the embodiment shown in figure 6 comprises a clamp (7) with two jaws which traps the defective tape (4) to allow its removal.
  • Figure 6 discloses two different embodiments, the clamp (7) being located below the pressure roller (6) or the clamp (7) being located over the pressure roller (6).
  • the deployment of the jaws of the clamp (7) can be done by a longitudinal sliding movement, a rotational one, a telescopic extension or any other movement or combination of movements. These movements can be electric, pneumatic or any alternative considered appropriate.
  • the catching step and the cutting step may be performed in any order:
  • the removal of the defective tape (4) will be done by rewinding the defective tape (4) around the clamp (7) as shown in figure 9 , preferably at a speed coordinated with the backwards movement of the lying head. Finally, a replacement tape (2) is laid-up by the automated tape placement machine after removal of the defective tape (4) as shown in figure 10 .
  • the clamp (7) comprises two external shells (9) and two internal cores (8) located in the shells (9) located in an opposite configuration and that behaves as a clamp to grab the defective tape (4).
  • the internal cores (8) are movable with respect to the external shells (9) such that they trap the defective tape (4) in-between when approach each other and release the defective tape (4) when move away from each other.
  • the clamp (7) comprises means for rewinding the defective tape (4) around the clamp (7), specifically, the defective tape (4) will be rewinded around the external shells (9) when the clamp (7) turns.
  • Figure 11 shows a first step in which the clamp (7) has both internal cores (8) separated so that the defective tape (4) is located in-between
  • figure 12 shows the internal cores (8) located against each other so that the defective tape (4) is caught by them and the turning of the clamp (7) makes the defective tape (4) to rewind over the external shells (9).
  • Figure 13 shows the retraction of the inner cores (8) into the external shells (9) therefore liberating the defective tape (4).
  • figure 14 shows one of the possible embodiments for releasing the defective tape (4) from the clamp (7) using a sliding arm (10) moving between the internal cores (8) in a direction parallel to the turning axis of the clamp (7) so that the sliding arm (10) pushes out the rolled defective tape (4).
  • the release and remove steps would be preferably done in a scrap area located in the laying zone or integrated in the head or the structure of the machine, this last option reduces the number of movements of the machine but increase the size, weight and complexity of the machine so the solution will be adapted to each case.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Robotics (AREA)
  • Moulding By Coating Moulds (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

Method for reworking a composite laminate (1) comprising a plurality of tapes (2), the method comprising the following steps:- detecting the occurrence of a defect (3) on a tape (4) of composite material while the tape (4) is being laid up,- continuing the lay-up of the defective tape (4) until a tape (4) length which surpasses a manufacturing length (L) of the tape (4),- catching the part of the defective tape (4) that surpasses the manufacturing length (L) of the tape (4),- cutting the defective tape (4) in the part of the defective tape (4) that surpasses the manufacturing length (L) of the tape (4),- removing from the laminate (1) the caught defective tape (4) by the catching system, and- laying-up a replacement tape (2) in the place of the removed defective tape (4).

Description

    Field of the invention
  • The invention relates to the automated manufacturing of fibre reinforced composite laminates by using automated tape or tow placement machines. The invention is applicable to all the parts of the structure of an aircraft or any composite part out of aerospace field.
    • Background of the invention
  • Laminates comprising a plurality of plies of composite are known, these laminates are being laid up by an automated tape placement machine comprising a laying head which lays one tape or a plurality of tapes per trajectory of the laying head. The plurality of tapes laid in a trajectory are usually named as course.
  • Nowadays, the manufacturing process of fibre reinforced plastic parts, typically named as composite parts, is highly automated by using tape placement machines, both in the case of using resin preimpregnated tapes or dry tapes. Figure 1 shows a schematic of a typical tape placement machine end effector with two laying heads.
  • In a tape placement machine, the movement of the machine itself allows the deposition of the tape. The action of a pressure roller and the eventual use of a heat source, whose presence and characteristics depends on the characteristics of the tape, allows the adherence of the tape to the laying tool or the laminate deposited in previous operations.
  • To end the laying, the tape is clamped and cut using a blade or alternative system, for instance, in figure 2 the clamping is done using the adding rollers.
  • Despite the high level of automation of the tape deposition, when a defect is detected during or after laying, the rework has to be done manually by an operator using a blade knife or other instrument to remove the defective tape. The replacement of the removed tapes can be then done manually or using again the automated placement machine.
    • Summary of the invention
  • The object of the invention is the improvement of the automated process of manufacturing composite laminates. The advantages with respect to the prior art are the systematisation of the rework process, improving the quality of the laminate after the rework, the eventual lead time and labour savings and the enabling of full automation of the composite laying operations.
  • It is one of the objects of the invention a method that comprises the following steps:
    • detecting the occurrence of a defect on a tape of composite material while the tape is being laid up,
    • continuing the lay-up of the defective tape until a tape length which surpasses a manufacturing length of the tape, i.e., a design length or a predetermined length at which the tape will be manufactured,
    • catching the part of the defective tape that surpasses the manufacturing length of the tape by a catching system,
    • cutting the defective tape by the automated tape placement machine in the part of the defective tape which surpasses the manufacturing length of the tape,
    • removal from the laminate of the caught defective tape by the catching system, and
    • laying-up a replacement tape by the automated tape placement machine after removal of the defective tape.
  • According to the above, the detection of the defect is performed simultaneously to the laying up process of the tape. In one embodiment of the invention the use of an online automated inspection system to detect the occurrence of a defect during the laying process is used, although the detection can have different levels of automation, from direct visual detection by an operator up to real time full automated defect detection/identification implying the coordination with a defect detection system.
  • Once the defect is detected, the lay-up process of the defective tape is continued until the end of the course, specifically extending an additional length over the predetermined or design length of the tape.
  • In that moment, the head of the machine could perform a movement to separate the laying head from the laminate, in one embodiment allowing the deployment of the rework system.
  • The next operation will be catching and removal of the defective tape or tapes by the catching system itself. When the tapes are removed, the rework system may retract to avoid interference with the laying heads and the replacement tapes will be laid by the machine as previously stated. The catching step and the cutting step may be performed in any order as long as the defective tape is cut and catch by the catching system.
  • It is also an object of the present invention a reworking system and an automated tape placement machine comprising said reworking system.
  • The reworking system object of the invention comprises the catching system comprising means configured for catching the defective tape when the occurrence of a defect on the tape or plurality of tapes is detected during the laying of the tape and comprising means for removing the caught defective tape from the laminate.
  • The automated tape placement machine object of the invention therefore comprises a reworking system according to the above and further comprises:
    • means for receiving a signal that a defect has occurred on a tape that is being laid-up,
    • means for continuing the lay-up of a defective tape until a tape length which surpasses the manufacturing length of the tape,
    • means for sending a signal to the reworking system for catching the part of the defective tape which surpasses the manufacturing length of the tape and for removing the defective tape,
    • means for cutting the defective tape before being removed, and
    • means for laying-up a replacement tape after removal of the defective tape.
    Description of the figures
  • To complete the description and in order to provide for a better understanding of the invention, a set of drawings is provided. Said drawings form an integral part of the description and illustrate preferred embodiments of the invention. The drawings comprise the following figures.
    • Figure 1 shows a schematic representation of an automated tape placement machine.
    • Figure 2 shows a schematic representation of the cutting process in an automated tape placement machine.
    • Figure 3 shows a schematic representation of a first step of the invention in which a defect on a tape that is being laid is detected.
    • Figure 4 shows a schematic representation of an additional step of the invention in which the laying-up process of the defective tape is continued until the end of a course.
    • Figure 5 shows a schematic representation of a next step of the invention in which the pressure roller is separated from the laminate.
    • Figure 6 shows a schematic representation of a next step of the invention in which two different embodiments of the rework system catch the defective tape.
    • Figures 7 y 8 shows a schematic representation of another embodiment in which the defective tape is firstly cut and afterwards the pressure roller is lifted from the laminate.
    • Figure 9 shows a schematic representation of a next step of the invention in which the rework system rewinds the tape for its removal.
    • Figure 10 shows a schematic representation of a next step of the invention in which the defective tape is replaced by a new one.
    • Figure 11 shows a schematic representation of an embodiment of the catching element of the rework system.
    • Figure 12 shows a schematic representation of the rewind step of the catching element of the embodiment of figure 11.
    • Figure 13 shows a schematic representation of the release step of the catching element of the embodiment of figure 11.
    • Figure 14 shows a schematic representation of the removal step of the catching element of the embodiment of figure 11.
    Detailed description of the invention
  • Figure 1 discloses a known automated taped placement machine manufacturing a laminate (1) over a mould (100) by laminating tapes (2) by means of two heads comprising at least a pressure roller (6), addition rollers (5) and cutters (50). In figure 2 the tape (2) is clamped using the adding rollers (5) and cut using a blade or alternative system to end the laying.
  • Figure 3 shows the detection of a defect (3) on a tape (4) while the tape (4) is being laid up. Afterwards, the lay-up of the defective tape (4) is continued until a tape (4) length that surpasses the manufacturing length (L) of the tape (4) as represented in figure 4. By rotation of the adding rollers (5) the defective tape (4) is placed between the pressure roller (6) and the laying surface to continue the lying operation.
  • In a multi-head machine, when laying multiple tapes (2), all the tapes (2) except the defective ones (4) are laid and cut according to the length of the original design of the part, except the defective ones (4) and those that may be selected to be also removed, that are extended an additional length. Therefore, the automated tape placement machine once a signal of a defected tape (4) is received continues the lay-up of a defective tape (4) until a tape (4) length that surpasses the manufacturing length (L) of the tape (4).
  • In an embodiment, the catching system is deployed after detecting the occurrence of a defect (3) and retracted after removal of the defective tape (4). For allowing the mentioned deployment of the catching system, the lying head may be separated from the defective tape (4), more specifically, as shown in figure 5, the pressure roller (6) is lifted from the laminate (1).
  • The catching system of the embodiment shown in figure 6 comprises a clamp (7) with two jaws which traps the defective tape (4) to allow its removal. Figure 6 discloses two different embodiments, the clamp (7) being located below the pressure roller (6) or the clamp (7) being located over the pressure roller (6).
  • The deployment of the jaws of the clamp (7) can be done by a longitudinal sliding movement, a rotational one, a telescopic extension or any other movement or combination of movements. These movements can be electric, pneumatic or any alternative considered appropriate.
  • As previously commented, the catching step and the cutting step may be performed in any order:
    • once the defective tape (4) or tapes (4) are clamped, the cutter (50) cuts them according to figure 6, or
    • alternatively, the defective tapes (4) to be removed are firstly cut and afterwards are clamped according to figures 7 and 8.
  • The removal of the defective tape (4) will be done by rewinding the defective tape (4) around the clamp (7) as shown in figure 9, preferably at a speed coordinated with the backwards movement of the lying head. Finally, a replacement tape (2) is laid-up by the automated tape placement machine after removal of the defective tape (4) as shown in figure 10.
  • As represented in the embodiment shown in figures 11 to 14, in order to have the catching system always ready for the next rework operation, it is advisable to allow an automated release of the removed defective tape (4).
  • In one embodiment, the clamp (7) comprises two external shells (9) and two internal cores (8) located in the shells (9) located in an opposite configuration and that behaves as a clamp to grab the defective tape (4). The internal cores (8) are movable with respect to the external shells (9) such that they trap the defective tape (4) in-between when approach each other and release the defective tape (4) when move away from each other. The clamp (7) comprises means for rewinding the defective tape (4) around the clamp (7), specifically, the defective tape (4) will be rewinded around the external shells (9) when the clamp (7) turns.
  • Figure 11 shows a first step in which the clamp (7) has both internal cores (8) separated so that the defective tape (4) is located in-between, figure 12 shows the internal cores (8) located against each other so that the defective tape (4) is caught by them and the turning of the clamp (7) makes the defective tape (4) to rewind over the external shells (9). Figure 13 shows the retraction of the inner cores (8) into the external shells (9) therefore liberating the defective tape (4).
  • Finally, figure 14 shows one of the possible embodiments for releasing the defective tape (4) from the clamp (7) using a sliding arm (10) moving between the internal cores (8) in a direction parallel to the turning axis of the clamp (7) so that the sliding arm (10) pushes out the rolled defective tape (4).
  • The release and remove steps would be preferably done in a scrap area located in the laying zone or integrated in the head or the structure of the machine, this last option reduces the number of movements of the machine but increase the size, weight and complexity of the machine so the solution will be adapted to each case.

Claims (13)

  1. Method for reworking a composite laminate (1), the laminate (1) comprising a plurality of tapes (2) of composite that are being laid up by an automated tape placement machine comprising a lying head, characterised in that the method comprises the following steps:
    - detecting the occurrence of a defect (3) on a tape (4) of composite material while the tape (4) is being laid up,
    - continuing the lay-up of the defective tape (4) until a tape (4) length which surpasses a manufacturing length (L) of the tape (4),
    - catching the part of the defective tape (4) that surpasses the manufacturing length (L) of the tape (4) by a catching system,
    - cutting the defective tape (4) in the part of the defective tape (4) that surpasses the manufacturing length (L) of the tape (4),
    - removing from the laminate (1) the caught defective tape (4) by the catching system, and
    - after removal of the defective tape (4) laying-up a replacement tape (2) in the place of the removed defective tape (4) by the automated tape placement machine.
  2. Method for reworking a composite part, according to claim 1, wherein an automated inspection system is provided for detecting the occurrence of a defect (3).
  3. Method for reworking a composite part, according to any preceding claim, wherein the catching system will be deployed over the laminate (1) after detecting the occurrence of a defect (3) and retracted from the laminate (1) after removal of the defective tape (4).
  4. Method for reworking a composite part, according to claim 3, wherein before the deployment of the catching system, the lying head is separated from the defective tape (4).
  5. Method for reworking a composite part, according to any preceding claim, wherein the catching system comprises a clamp (7) with two jaws which trap the defective tape (4) in-between.
  6. Method for reworking a composite part, according to claim 5, wherein the removal of the defective tape (4) is done by rewinding the defective tape (4) around the clamp (7).
  7. Method for reworking a composite part, according to any preceding claim, wherein the defective tape (4) is cut after being caught by the catching system.
  8. Reworking system for a composite laminate (1) comprising a plurality of tapes (2) of composite configured for being laminated by an automated tape placement machine comprising a laying head characterised in that the reworking system comprises a catching system comprising means configured for catching a defective tape (4) when the occurrence of a defect (3) on the tape (4) is detected during the laying of the tape (4) and the catching system comprising means for removing the caught defective tape (4) from the laminate (1).
  9. Reworking system for a composite laminate, according to claim 8, wherein it comprises a clamp (7) with two jaws configured for trapping the defective tape (4) in-between.
  10. Reworking system for a composite laminate, according to claim 9, wherein the clamp (7) comprises means for rewinding the defective tape (4) around the clamp (7).
  11. Reworking system for a composite laminate, according to claim 8 or 9, wherein the clamp (7) comprises two external shells (9) and two internal cores (8) located in the external shells (9) and in an opposite location, the internal cores (8) being movable with respect to the external shells (9) such that they trap the defective tape (4) in-between when approaches each other and release the defective tape (4) when move away from each other.
  12. Reworking system for a composite laminate, according to claim 11, wherein the defective tape (4) is rewind around the external shells (9).
  13. Automated tape placement machine characterised in that it comprises a reworking system according to any preceding claim 8 to 12 and in that it further comprises:
    - means for receiving a signal that a defect (3) has occurred on a tape (4) that is being laid-up,
    - means for continuing the lay-up of a defective tape (4) until a tape (4) length that surpasses the manufacturing length (L) of the tape (4),
    - means for sending a signal to the reworking system for catching the part of the defective tape (4) that surpasses the manufacturing length (L) of the tape (4) and for removing the defective tape (4),
    - means (50) for cutting the defective tape (4) in the part of the defective tape (4) that surpasses the manufacturing length (L) of the tape (4) before being removed,
    - means for laying-up a replacement tape (2) after removal of the defective tape (4).
EP18382747.6A 2018-10-19 2018-10-19 Method and system for reworking a composite laminate Active EP3640012B1 (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
EP18382747.6A EP3640012B1 (en) 2018-10-19 2018-10-19 Method and system for reworking a composite laminate
CA3056864A CA3056864A1 (en) 2018-10-19 2019-09-26 Method and system for reworking a composite laminate
KR1020190125755A KR102502355B1 (en) 2018-10-19 2019-10-11 Method and system for reworking a composite laminate
US16/655,414 US11104084B2 (en) 2018-10-19 2019-10-17 Method and system for reworking a composite laminate
CN201910994173.2A CN111070731B (en) 2018-10-19 2019-10-18 Method and system for reprocessing composite laminates and automatic tape laying machine

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP18382747.6A EP3640012B1 (en) 2018-10-19 2018-10-19 Method and system for reworking a composite laminate

Publications (2)

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EP3640012A1 true EP3640012A1 (en) 2020-04-22
EP3640012B1 EP3640012B1 (en) 2026-04-01

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EP (1) EP3640012B1 (en)
KR (1) KR102502355B1 (en)
CN (1) CN111070731B (en)
CA (1) CA3056864A1 (en)

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ES2966314T3 (en) * 2021-01-29 2024-04-19 Airbus Operations Slu Method for determining the peel energy of a composite laminate
CN113059829B (en) * 2021-03-09 2022-03-25 北京航空航天大学 Synchronous collecting mechanism for isolating films of thermosetting fiber prepreg tapes
US20240181665A1 (en) * 2021-03-19 2024-06-06 Vibracoustic Cv Air Spring Otomotiv Sanayi Ve Ticaret Anonim Sirketi Automatic apparel machine

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WO2016179616A1 (en) * 2015-05-12 2016-11-17 Fill Gesellschaft M.B.H. Gripper having at least one clamping element

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KR102502355B1 (en) 2023-02-21
CN111070731A (en) 2020-04-28
CN111070731B (en) 2023-07-18
US11104084B2 (en) 2021-08-31
US20200122412A1 (en) 2020-04-23
EP3640012B1 (en) 2026-04-01
CA3056864A1 (en) 2020-04-19
KR20200045402A (en) 2020-05-04

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